An ultra-high voltage compensation type air-electric hybrid water-tight cable and a manufacturing method thereof

Abstract

The application discloses an ultrahigh-pressure compensation type gas-electricity hybrid water-proof cable and a manufacturing method, and particularly relates to the technical field of cables, which comprises an ultrahigh-pressure gas unit arranged at a center position, a plurality of power supply units and a plurality of signal transmission units arranged around the outside of the ultrahigh-pressure gas unit, cable water-blocking glue filled in cable gaps, a wrapping water-blocking belt wrapped outside the water-blocking glue, a high-strength polyurethane inner sheath extruded outside the wrapping water-blocking belt, a tensile layer formed by high-strength aramid fiber SZ double-layer bundle armor arranged outside the inner sheath, and a high-strength polyurethane outer sheath extruded outside the tensile layer. The ultrahigh-pressure gas compensation, power transmission and signal transmission are integrated, and the synergistic effect of the aramid woven pressure-resistant layer and the aramid SZ double-layer bundle armor enables the cable to withstand an ultrahigh water pressure of more than 20 MPa, thereby providing reliable guarantee for the long-term stable operation of deep-sea equipment.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and more specifically, to an ultra-high voltage compensated gas-electric hybrid watertight cable and its manufacturing method. Background Technology

[0002] In fields such as deep-sea exploration and marine resource development, extremely high demands are placed on the performance and reliability of underwater equipment. As a key component, underwater acoustic transducers need to operate stably in the complex deep-sea environment. However, with increasing water depth, water pressure increases dramatically, posing a significant challenge to the cables connecting the underwater acoustic transducers to external equipment.

[0003] Traditional watertight cables have relatively limited functionality, often only capable of transmitting power or signals, making it difficult to meet the multi-functional integration requirements of modern underwater equipment. For example, some underwater equipment is prone to damage or performance degradation due to internal and external pressure differences during operation. Existing cables cannot effectively compensate for pressure, failing to guarantee the normal operation of equipment under high-pressure environments.

[0004] Furthermore, in the deep-sea environment, cables must withstand enormous tensile forces, corrosion, and the impact of water currents. The structure and materials of ordinary cables are ill-suited to such harsh conditions, easily leading to breakage and decreased insulation performance, severely impacting the normal operation and lifespan of equipment.

[0005] Currently, traditional solutions for connecting these deep-sea devices mainly face the following problems and challenges:

[0006] 1. Limited Functionality, Complex System: Traditional cables or hoses have limited functionality. Power cables can only supply power, signal cables can only transmit data, and pressure compensation requires additional gas piping. To meet equipment requirements, multiple independent cables often need to be laid simultaneously, which greatly increases system complexity, occupies valuable space and weight, and incurs high deployment and maintenance costs.

[0007] 2. Insufficient pressure compensation capability: In existing technologies, even when gas tubing is integrated, some cables have limited pressure resistance, typically unable to withstand pressures exceeding 10 MPa, thus restricting the equipment's use in deeper waters (e.g., depths exceeding 1000 meters). Furthermore, the stability and sealing of gas transmission are difficult to guarantee over long periods under high pressure.

[0008] 3. Incompatibility of mechanical properties with the deep-sea environment: The deep-sea environment involves enormous hydrostatic pressure, frequent or continuous dynamic tension, and seawater corrosion. While the metal armor layer of traditional cables (such as steel wire) is strong, it is heavy and susceptible to corrosion in seawater. Its bending performance is also poor, making it unsuitable for applications requiring frequent deployment or dynamic positioning. Furthermore, in the complex electromagnetic environment, the reliability of signal transmission is difficult to guarantee.

[0009] Therefore, developing an integrated watertight cable that can simultaneously achieve ultra-high pressure gas compensation, efficient power transmission, and high-speed signal transmission, while possessing excellent mechanical properties and adaptability to the deep-sea environment, is an urgent problem to be solved in the field of marine engineering technology. Summary of the Invention

[0010] In order to overcome the above-mentioned defects of the prior art, the embodiments of the present invention provide an ultra-high voltage compensated gas-electric hybrid watertight cable and a manufacturing method thereof. The technical problem to be solved by the present invention is that the existing cables have limited functionality in deep-sea high-pressure environments, cannot meet the diverse needs of equipment, and have low reliability.

[0011] To achieve the above objectives, the present invention provides the following technical solution: an ultra-high voltage compensated gas-electric hybrid watertight cable, comprising an ultra-high voltage gas unit, several power supply units, several signal transmission units, cable water-blocking adhesive, wrapping water-blocking tape, inner sheath, tensile layer and outer sheath;

[0012] The ultra-high pressure gas unit is located at the center of the cable and is used to transmit high-pressure compensation gas. The ultra-high pressure gas unit comprises, from the inside out: an inner wall of the gas tube made of polyurethane material, a mesh-like pressure-resistant layer woven from aramid fibers, and a polyurethane gas tube sheath extruded over the pressure-resistant layer. The polyurethane hose, serving as the inner wall of the gas tube, possesses excellent flexibility and sealing properties, ensuring stable gas transmission within the tube. The mesh-like pressure-resistant layer woven from aramid fibers utilizes the high strength and corrosion resistance of aramid fibers to effectively resist deep-sea pressure, providing reliable radial support for the inner wall of the gas tube. The polyurethane gas tube sheath further enhances the pressure resistance and sealing performance of the gas unit.

[0013] Several power supply units are located outside the ultra-high pressure gas unit for transmitting electrical energy. Each power supply unit includes a stranded tin-plated copper conductor I and a cross-linked polyethylene insulation layer extruded around the conductor I. The stranding design increases the flexibility of the conductor, facilitating cable laying and installation, while the tin plating layer improves the conductor's oxidation resistance and conductivity. The cross-linked polyethylene material has excellent insulation properties and temperature resistance, effectively ensuring the stability of electrical energy during transmission, reducing losses, and adapting to different operating temperature environments.

[0014] Several signal transmission units are located outside the ultra-high pressure gas unit for transmitting data signals. Each signal transmission unit includes two stranded tin-plated copper conductors II, a polytetrafluoroethylene (PTFE) insulation layer extruded over each conductor II, an aluminum-plastic composite tape shielding layer wrapped around the two PTFE insulation layers, and a tin-plated copper wire braided shielding layer woven over the aluminum-plastic composite tape shielding layer. PTFE, as a high-temperature resistant insulation layer, maintains good insulation performance in high-temperature environments, ensuring the signal is not interfered with. The aluminum foil shielding of the aluminum-plastic composite tape shielding layer effectively blocks external electromagnetic interference. The tin-plated copper wire braided shielding layer further enhances the shielding effect, ensuring the stability and reliability of signal transmission.

[0015] Water-blocking adhesive is filled into the gaps between several power supply units and several signal transmission units after they are cabled. The water-blocking adhesive can effectively prevent water from seeping into the cable, ensuring the insulation performance and service life of the cable. Water-blocking tape is wrapped around the outside of the water-blocking adhesive to secure it and further enhance the water-blocking effect of the cable.

[0016] The inner sheath is extruded around the outside of the water-blocking tape and is made of high-strength elastomer polyurethane material. This material has excellent wear resistance, corrosion resistance and flexibility, which can provide good protection for the cable core and resist the erosion of the external environment.

[0017] The tensile layer is located outside the inner sheath and is armored with high-strength aramid fibers using a double-layer SZ stranding method, and is designed with torque balance. This armoring structure can not only significantly improve the tensile strength of the cable, but also ensure that the cable will not generate excessive torque during bending and other operations, thus avoiding damage to the internal structure.

[0018] The outer sheath is extruded over the tensile layer and is made of high-strength elastomer polyurethane material. It works in conjunction with the inner sheath to further enhance the cable's protective performance, enabling the cable to adapt to the use requirements of harsh environments such as deep sea.

[0019] In a preferred embodiment, the inner diameter of the gas pipe of the ultra-high pressure gas unit ranges from 4mm to 6mm, and the wall thickness ranges from 1mm to 3mm. This ensures both the flow rate requirement for gas transmission and the structural stability of the gas pipe under ultra-high pressure. If the inner diameter is too large, the circumferential stress on the pipe wall increases under high pressure, making it prone to rupture. If the inner diameter is too small, the gas flow rate is limited, failing to meet the response speed requirements for pressure compensation. By controlling the wall thickness of the gas pipe to 1mm to 3mm, it is ensured that the gas pipe will not experience radial collapse or bursting under ultra-high pressure environments above 20MPa.

[0020] In a preferred embodiment, the stranded tin-plated copper conductor I of the power supply unit is composed of multiple strands of tin-plated copper wire with a diameter ranging from 0.3 mm to 0.5 mm, and a stranding pitch ranging from 25 mm to 30 mm. The multi-strand fine wire stranding structure significantly improves the conductor's flexibility compared to a single-strand thick conductor, facilitating bending operations during deep-sea cable deployment. Simultaneously, the multi-strand stranding structure increases the conductor's surface area, which is beneficial for high-frequency current transmission and reduces additional losses due to the skin effect. Controlling the stranding pitch within the range of 25 mm to 30 mm ensures the compactness and stability of the conductor structure. Too small a pitch increases stranding costs and production difficulty, while too large a pitch may cause the conductor to loosen, affecting the cable's bending performance.

[0021] In a preferred embodiment, the insulation layer thickness of the two stranded tin-plated copper conductors II of the signal transmission unit ranges from 0.1mm to 0.2mm, the wrapping overlap rate of the aluminum-plastic composite tape shielding layer ranges from 20% to 30%, and the braiding density of the tin-plated copper wire braided shielding layer ranges from 85% to 90%. Controlling the insulation layer thickness to 0.1mm to 0.2mm ensures sufficient insulation strength while avoiding increased signal transmission attenuation due to excessive insulation thickness. The wrapping overlap rate of the aluminum-plastic composite tape shielding layer, ranging from 20% to 30%, ensures the continuity and integrity of the shielding layer; too low an overlap rate may lead to discontinuous shielding, while too high an overlap rate increases material costs and cable outer diameter. The braiding density of the tin-plated copper wire braided shielding layer, ranging from 85% to 90%, ensures excellent shielding performance, effectively resisting strong electric field interference from the internal power supply unit and electromagnetic noise from the complex external marine environment, guaranteeing high-fidelity transmission of weak signals over long distances and under high voltage conditions.

[0022] In a preferred embodiment, the thickness of the inner sheath ranges from 1.5 mm to 2 mm, and the thickness of the outer sheath ranges from 2 mm to 3 mm. The inner and outer sheaths are reasonably matched in thickness. The thickness of the inner sheath is 1.5 mm to 2 mm, which protects the cable core without excessively increasing the cable's outer diameter. The thickness of the outer sheath is 2 mm to 3 mm. As the main external protective layer, it provides sufficient wear resistance, corrosion resistance, and resistance to mechanical damage, ensuring the long-term reliability of the cable in harsh deep-sea environments.

[0023] This invention also includes a method for manufacturing an ultra-high voltage compensated gas-electric hybrid watertight cable, comprising the following steps:

[0024] S1: Preparation of high-pressure gas unit: Polyurethane hose is selected as the inner wall of the gas tube. Aramid fibers are woven on the outside of the inner wall of the gas tube to form a mesh-like pressure-resistant layer. Then, a polyurethane sheath is extruded on the outside of the pressure-resistant layer as the gas tube sheath, thereby obtaining the ultra-high pressure gas unit. In this step, the control of weaving tension and weaving density is the key to ensure that the aramid fibers are evenly and tightly interwoven on the outside of the inner wall of the gas tube to form an effective radial support structure.

[0025] S2: Preparation of power supply unit: Select stranded tin-plated copper conductor I, and extrude cross-linked polyethylene material on its outside to form a cross-linked polyethylene insulation layer, thereby obtaining the power supply unit; the control of extrusion temperature, speed and pressure directly affects the thickness uniformity and cross-linking degree of the insulation layer, and thus affects the insulation performance of the power supply unit;

[0026] S3: Preparation of the signal transmission unit: Select two stranded tin-plated copper conductors II, and extrude polytetrafluoroethylene (PTFE) onto the outside of each conductor II to form a PTFE insulation layer. Strand the two conductors II with PTFE insulation layers together, and wrap an aluminum-plastic composite tape around them as an aluminum-plastic composite tape shielding layer. Then, braid tin-plated copper wires around the aluminum-plastic composite tape shielding layer to form a tin-plated copper wire braided shielding layer, thereby obtaining the signal transmission unit. In this step, the extrusion thickness of the insulation layer, the wrapping overlap rate of the aluminum-plastic composite tape, and the braiding density of the tin-plated copper wires must be precisely controlled to ensure the electrical performance and shielding effect of the signal transmission unit.

[0027] S4: Forming the first common cable core: The ultra-high pressure gas unit, multiple power supply units, and multiple signal transmission units are cabled according to the predetermined arrangement. After cabling, the gaps are filled with cable water-blocking adhesive, and then water-blocking tape is wrapped around the outside to form the first common cable core. During the cabling process, the arrangement position of each unit and the cabling pitch must be strictly controlled to ensure the roundness of the cable core structure and the uniformity of stress on each unit.

[0028] S5: Forming the second sheath: High-strength elastomer polyurethane material is extruded onto the outside of the first sheath to form an inner sheath, thus obtaining the second sheath; the extrusion process parameters of the inner sheath directly affect the density of the sheath and the bonding strength with the cable core.

[0029] S6: Forming the third community: On the outside of the second community, high-strength aramid fibers are used for armoring in an SZ double-layer stranded armoring manner, and a torsional balance design is implemented to form the third community; specifically, the inner layer is stranded in a first direction, and the outer layer is stranded in a second direction opposite to the first direction. Torsional balance is achieved by precisely controlling the stranding direction and pitch of the inner and outer layers; this design eliminates the torsional force generated during the bending and unfolding of the armor layer;

[0030] S7: Forming the final cable: High-strength elastomer polyurethane material is extruded again on the outside of the third community to form an outer sheath, resulting in an ultra-high voltage compensated gas-electric hybrid watertight cable; the extrusion process control of the outer sheath is similar to that of the inner sheath, but attention should be paid to the surface quality and thickness uniformity of the outer sheath to ensure the overall protective performance of the cable.

[0031] In the above manufacturing method, the steps are interconnected and performed sequentially; among them, S1, S2, and S3 are independent preparation steps for each functional unit, and there is no restriction on the order of the three, which can be carried out simultaneously to improve production efficiency; S4 to S7 are subsequent integration steps, which need to be completed in a predetermined order.

[0032] In a preferred embodiment, in step S1, the inner diameter of the polyurethane hose ranges from 4 mm to 6 mm, and the wall thickness ranges from 1 mm to 3 mm; the braiding density of the aramid fiber is 6 to 8 knots per inch; the braiding density range ensures that the pressure-resistant layer has sufficient radial pressure resistance to effectively support the inner wall of the air tube against external water pressure of more than 20 MPa.

[0033] In a preferred embodiment, in step S3, the wrapping overlap rate of the aluminum-plastic composite strip shielding layer ranges from 20% to 30%, and the braiding density of the tin-plated copper wire braided shielding layer ranges from 85% to 90%. By controlling the above parameters, the signal transmission unit is ensured to have excellent electromagnetic shielding effect.

[0034] In a preferred embodiment, in step S6, the SZ double-layer stranded armor includes an inner layer stranded in a first direction and an outer layer stranded in a second direction opposite to the first direction to achieve torque balance; specifically, the inner layer uses left-hand stranding and the outer layer uses right-hand stranding; or the inner layer uses right-hand stranding and the outer layer uses left-hand stranding; through this alternating forward and reverse spiral armoring method, when the cable is subjected to tension, the torque generated by the inner and outer layers cancels each other out, so that the cable will not twist when subjected to tension, ensuring the structural stability of the cable in deep-sea vertical deployment and long-length suspension, and avoiding cable damage caused by torque accumulation.

[0035] The technical effects and advantages of this invention are as follows:

[0036] 1. This invention integrates an ultra-high pressure gas unit, a power supply unit, and a signal transmission unit into a single cable, achieving the fusion of three major functions: gas compensation, power supply, and signal transmission. The ultra-high pressure gas unit is located at the center of the cable, with the power supply unit and signal transmission unit arranged around its outer perimeter. This concentric layout is compact and reasonable, solving the problems of single-function systems and complex systems requiring multiple cables in existing technologies. It simplifies the deployment process of deep-sea equipment and reduces maintenance costs. At the same time, by setting up a double water-blocking structure of cable water-blocking adhesive and wrapping water-blocking tape, combined with inner and outer double-layer polyurethane sheaths, a complete multi-layer waterproof barrier is constructed, ensuring the water tightness of the cable in ultra-high pressure environments above 20MPa, providing a reliable guarantee for the long-term stable operation of deep-sea equipment.

[0037] 2. The ultra-high pressure gas unit in this invention adopts a three-layer composite structure, with an aramid braided layer as the middle skeleton. Utilizing the ultra-high strength (tensile strength can reach over 3000MPa) and excellent seawater corrosion resistance of aramid fibers, it effectively resists the radial pressure of the deep-sea ultra-high pressure environment, protecting the unobstructed flow and structural integrity of the internal gas pipes. This enables the cable to stably transmit ultra-high pressure gas of over 20MPa. Working in conjunction with the power supply unit and signal transmission unit, it allows connected underwater acoustic transducers and other equipment to ensure gas exchange in the pressure compensator through inflation, thereby ensuring the internal and external pressure balance of the equipment.

[0038] 3. This invention uses an SZ double-layer stranded armor structure of aramid fiber as a tensile layer and introduces a torsional balance design. Compared with traditional steel wire armor, the density of aramid fiber is only about 1 / 5 of that of steel. Under the premise of meeting the requirements of long-length suspension in deep sea, the overall weight of the cable is greatly reduced. The SZ double-layer stranding method eliminates the torsional force generated by the armor layer during bending and unwinding, which greatly improves the service life and operational reliability of the cable. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the overall cross-sectional structure of the present invention.

[0040] Figure 2 This is a schematic diagram of the cross-sectional structure of the ultra-high pressure gas unit of the present invention.

[0041] Figure 3 This is a schematic diagram of the cross-sectional structure of the power supply unit of the present invention.

[0042] Figure 4 This is a schematic diagram of the cross-sectional structure of the signal transmission unit of the present invention.

[0043] The attached diagram is labeled as follows: 1 Ultra-high pressure gas unit, 2 Power supply unit, 3 Signal transmission unit, 6 Tensile layer;

[0044] 11 Tracheal inner wall, 12 Pressure-resistant layer, 13 Tracheal sheath;

[0045] 21 Conductor I, 22 Cross-linked polyethylene insulation layer;

[0046] 31 Conductor II, 32 Poly(fluoroethylene) propylene insulation layer, 33 Aluminum-plastic composite tape shielding layer, 34 Tinned copper wire braided shielding layer;

[0047] 41 Cable water-blocking adhesive; 42 Water-blocking wrapping tape;

[0048] 51 Inner sheath, 52 Outer sheath. Detailed Implementation

[0049] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] Example 1: Preparation of Ultra-High Voltage Compensated Gas-Electric Hybrid Watertight Cable

[0051] This embodiment provides an ultra-high voltage compensated gas-electric hybrid watertight cable and its manufacturing method, the specific steps of which are as follows:

[0052] S1: Preparation of high-pressure gas unit 1: A polyurethane hose with an inner diameter of 5 mm and a wall thickness of 1.5 mm is selected as the inner wall of the gas tube 11. It has good flexibility and initial sealing performance, which can meet the requirements of gas transmission.

[0053] Using aramid fiber weaving equipment, aramid fibers (using 1920D aramid fibers) are woven at a density of 7 knots per inch on the outer side of the tracheal inner wall 11 to form a mesh-like pressure-resistant layer 12. During the weaving process, the weaving tension is strictly controlled at 5-8N to ensure that the aramid fibers are tightly interwoven, and the thickness of the pressure-resistant layer 12 reaches 1.0mm to effectively resist the ultra-high pressure of the deep sea.

[0054] The air tube with the braided pressure-resistant layer 12 is extruded through an extruder to form a polyurethane sheath 13 with a thickness of 1.0 mm under the conditions of extrusion temperature of 190℃ and extrusion pressure of 15MPa, thereby obtaining the ultra-high pressure air unit 1.

[0055] S2: Preparation of power supply unit 2: Seven tin-plated copper wires with a diameter of 0.4 mm are stranded together using a stranding device to form stranded tin-plated copper conductor I21. During the stranding process, the stranding pitch is controlled at 28 mm to ensure that the conductor has good flexibility and conductivity.

[0056] The stranded tin-plated copper conductor I21 is fed into an extruder. In the extruder, cross-linked polyethylene material is melted at an extrusion temperature of 220°C and extruded with appropriate extrusion pressure to uniformly coat the outside of the stranded tin-plated copper conductor I21, forming a cross-linked polyethylene insulation layer 22 with a thickness of 0.8 mm, thus obtaining the power supply unit 2.

[0057] S3: Preparation of signal transmission unit 3: Seven tin-plated copper wires with a diameter of 0.18 mm are selected and stranded using a stranding device to prepare two stranded tin-plated copper conductors II 31. The two stranded tin-plated copper conductors II 31 are fed into a high-temperature extruder. In the high-temperature extruder, polytetrafluoroethylene propylene material is melted at an extrusion temperature of 350℃ and extruded with appropriate extrusion pressure, uniformly coating the outside of the stranded tin-plated copper conductors II 31 to form a polytetrafluoroethylene propylene insulation layer 32 with a thickness of 0.15 mm.

[0058] Two conductors II 31 with polytetrafluoroethylene propylene insulation layer 32 are twisted together with a pitch of 40 mm. Then, aluminum-plastic composite tape is wrapped around the outside of the stranded wire as aluminum-plastic composite tape shielding layer 33 using an aluminum-plastic composite tape wrapping device with a wrapping overlap rate of 25%.

[0059] On the outside of the aluminum-plastic composite tape shielding layer 33, a tin-plated copper wire braiding device is used to weave a mesh of tin-plated copper wire at a braiding density of 88%, forming a tin-plated copper wire braided shielding layer 34, thus obtaining the signal transmission unit 3.

[0060] S4: Forming the first common cable core: The prepared ultra-high pressure air unit 1, seven power supply units 2, and four signal transmission units 3 are arranged in a predetermined pattern, with the ultra-high pressure air unit 1 in the center and the power supply units 2 and signal transmission units 3 interleaved around the outside. During the cabling process, the cabling pitch is controlled at 200mm to ensure that the units are evenly distributed and to avoid twisting and compression.

[0061] After cabling, a special injection device is used to inject cable water-blocking adhesive 41 into the gaps at a pressure of 2MPa to ensure that the water-blocking adhesive fully fills all gaps.

[0062] Using a wrapping device, two layers of water-blocking tape 42 are wrapped around the outside of the cable core filled with cable water-blocking adhesive 41, with a wrapping overlap rate of 50%, forming the first common cable core.

[0063] S5: Forming the second community: The first community cable core is fed into an extruder. In the extruder, high-strength elastomer polyurethane material melts at an extrusion temperature of 200°C and is extruded at an extrusion pressure of 18MPa, uniformly covering the outside of the first community cable core to form an inner sheath 51 with a thickness of 1.8mm, thus forming the second community.

[0064] S6: Formation of the Third Community: On the outside of the second community, using armoring equipment, high-strength aramid fibers of specification 4800D are armored using an SZ double-layer stranding armoring method. During the armoring process, the inner layer is stranded with a pitch ratio of 55° to the left and a pitch of 150mm, while the outer layer is stranded with a pitch ratio of 55° to the right and a pitch of 150mm. By precisely controlling the opposite stranding directions and pitch matching of the inner and outer layers, a torsional balance design is achieved, forming tensile layer 6, thus obtaining the third community.

[0065] S7: Forming the final cable: The third community is fed into the extruder. In the extruder, the high-strength elastomer polyurethane material melts at an extrusion temperature of 200°C and is extruded at an extrusion pressure of 18MPa, uniformly covering the outside of the third community to form an outer sheath 52 with a thickness of 2.5mm, finally obtaining an ultra-high voltage compensated gas-electric hybrid watertight cable.

[0066] Performance testing:

[0067] A series of performance tests were conducted on the prepared ultra-high voltage compensated gas-electric hybrid watertight cable. The test results are as follows:

[0068] Gas transmission performance: Under a high pressure environment of 20MPa, the ultra-high pressure gas unit 1 can stably transmit gas with a gas leakage rate of less than 0.5% / h. The cable will not deform under high water pressure, meeting the requirements of pressure compensation.

[0069] Power transmission performance: Under AC 1000V and current 50A conditions, power supply unit 2 has good insulation performance, no breakdown phenomenon, and insulation resistance greater than 10000MΩ·km.

[0070] Signal transmission performance: At a frequency of 1MHz, the signal transmission unit 3 has a signal transmission attenuation of less than 1.5dB / 100m, good shielding effect, minimal impact of external electromagnetic interference on signal transmission, and shielding attenuation greater than 60dB.

[0071] Tensile strength: The cable does not break when subjected to a tensile force of 80kN, and its tensile strength meets the requirements for use in deep-sea environments up to 2000 meters deep.

[0072] Waterproof performance: After being subjected to a high water pressure of 20MPa for 24 hours, there was no water ingress inside the cable, demonstrating excellent waterproof performance.

[0073] Bending performance: After the cable is bent 10 times around a cylinder with a diameter of 1m, the sheath does not crack and all units function normally, meeting the bending requirements for deep-sea deployment and retrieval operations.

[0074] Example 2: Manufacturing of Cables of Different Specifications

[0075] This embodiment provides a method for manufacturing another specification of ultra-high voltage compensated gas-electric hybrid watertight cable, the specific steps of which are as follows:

[0076] S1: Preparation of High-Pressure Gas Unit 1: A polyurethane hose with an inner diameter of 6 mm and a wall thickness of 2 mm is selected as the inner wall 11 of the gas tube. Aramid is braided on the outside of the inner wall 11 at a density of 8 knots per inch, with the braiding tension controlled at 6-10 N, forming a pressure-resistant layer 12 with a thickness of 1.2 mm. Subsequently, under the conditions of extrusion temperature of 195℃ and extrusion pressure of 16 MPa, a polyurethane gas tube sheath 13 with a thickness of 1.5 mm is formed, thus obtaining the ultra-high pressure gas unit 1.

[0077] S2: Preparation of power supply unit 2: Nineteen tin-plated copper wires with a diameter of 0.45 mm are stranded together with a stranding pitch of 30 mm to form a stranded tin-plated copper conductor I21. Cross-linked polyethylene material is extruded on its exterior to form a cross-linked polyethylene insulation layer 22 with a thickness of 0.9 mm, thus obtaining power supply unit 2.

[0078] S3: Preparation of signal transmission unit 3: Seven tin-plated copper wires with a diameter of 0.2 mm are selected to prepare two stranded tin-plated copper conductors II 31. Polytetrafluoroethylene propylene is extruded on the outside of each conductor II 31, with an insulation layer thickness of 0.18 mm. The two conductors II 31 with insulation layers are stranded at a pitch of 50 mm and wrapped with aluminum-plastic composite tape as aluminum-plastic composite tape shielding layer 33, with a wrapping overlap rate of 28%. Then, tin-plated copper wire is braided to form tin-plated copper wire braided shielding layer 34 with a braiding density of 90%, thus obtaining signal transmission unit 3.

[0079] S4 to S7: Subsequent steps:

[0080] Following a method similar to that in Example 1, the following operations were performed: cabling, filling with water-blocking adhesive, wrapping with water-blocking tape, extruding an inner sheath, applying aramid SZ double-layer stranded armor, and extruding an outer sheath. The thickness of the inner sheath 51 was 2.0 mm, and the thickness of the outer sheath 52 was 3.0 mm, ultimately resulting in ultra-high voltage compensated gas-electric hybrid watertight cables of different specifications.

[0081] Performance testing: The cable of this specification was subjected to performance testing, and the test results also met the relevant standard requirements, indicating that the manufacturing method of the present invention has good versatility and can manufacture reliable ultra-high voltage compensated gas-electric hybrid watertight cables according to different usage requirements.

[0082] Example 3: Comparative Experiment

[0083] Comparative Example 1: A deep-sea cable with a structure that is basically the same as that of Example 1, except that its tensile layer uses a traditional double-layer steel wire armor instead of an aramid fiber SZ double-layer stranded armor.

[0084] Comparative Example 2: A deep-sea cable with a structure that is basically the same as that of Example 1, except that its ultra-high pressure gas unit 1 only includes the inner wall 11 of the polyurethane gas pipe and the gas pipe sheath 13, and does not include the mesh pressure-resistant layer 12 woven from aramid fibers.

[0085] The cables prepared in Example 1 and Comparative Examples 1-2 were subjected to performance testing, and the following data were obtained:

[0086] Performance comparison results

[0087] Comparison Projects Example 1 Comparative Example 1 Comparative Example 2 Weight per unit length Approximately 1.2 kg / m Approximately 2.5 kg / m Approximately 1.0 kg / m Minimum bending radius 250mm (5 times the outer diameter) 400mm (8 times the outer diameter) 220mm (4.5 times the outer diameter) Seawater corrosion resistance Excellent Poor (requires additional anti-corrosion measures) Excellent Torque balance performance excellent Poor excellent Air pipe condition under 20MPa water pressure Intact and undeformed Intact and undeformed Collapse and Deformation Maximum operating water depth >2000m >2000m <500m

[0088] From the comparison of the above data, we can see that:

[0089] Comparative Example 1 uses steel wire armor, which significantly increases cable weight under the same strength requirements, increasing the difficulty and cost of deep-sea deployment. Furthermore, steel wire armor is susceptible to corrosion in seawater, requiring additional anti-corrosion treatment and increasing maintenance costs. The minimum bending radius of steel wire armor is also relatively large (400mm), which is unfavorable for cable deployment in confined spaces. In addition, traditional steel wire armor lacks a torque balance design, easily leading to torque accumulation during deployment and retraction, resulting in cable damage. In contrast, Example 1 uses aramid fiber SZ double-layer stranded armor, which significantly reduces cable weight while maintaining strength, improves bending performance, and solves the torque problem.

[0090] Comparative Example 2's ultra-high pressure gas unit does not include an aramid braided pressure-resistant layer. Although the cable weight is further reduced, under ultra-high water pressure of 20 MPa, the inner wall of the gas pipe collapses and deforms due to the lack of radial support, causing blockage of the gas transmission channel and preventing the pressure compensation function from being achieved. The maximum working water depth is less than 500 m. In contrast, Comparative Example 1's ultra-high pressure gas units all include pressure-resistant layers and can maintain the integrity of the gas pipe under 20 MPa water pressure. However, Comparative Example 1's overall performance is inferior to Example 1 due to the large weight of the armor layer.

[0091] Working principle of this invention:

[0092] Refer to the instruction manual appendix Figure 1 The ultra-high pressure gas unit 1 is located at the center of the cable. From the inside out, it comprises a polyurethane-made gas tube inner wall 11, an aramid fiber woven mesh pressure-resistant layer 12, and a polyurethane gas tube sheath 13. High-pressure compensation gas is transmitted through the internal channels of the gas tube inner wall 11 to the pressure compensators of equipment such as underwater acoustic transducers. The pressure-resistant layer 12, woven from high-strength aramid fibers, bears the main radial pressure when the cable is subjected to high external water pressure, protecting the gas tube inner wall 11 from crushing and ensuring unobstructed gas flow. The power supply unit 2 and signal transmission unit 3 surround the outer side of the ultra-high pressure gas unit 1, respectively transmitting power and signals.

[0093] Further, please refer to the appendix to the instruction manual. Figure 1 and Figure 4 The signal transmission unit 3 adopts a double-layer shielding structure. The aluminum-plastic composite tape shielding layer 33 provides 100% coverage shielding, while the tinned copper wire braided shielding layer 34 provides 85%–90% braid density shielding. The two shielding methods complement each other to form a complete electromagnetic shielding system. When the cable simultaneously transmits high-current power and weak control signals, the strong electric field generated by the power supply unit 2 is effectively blocked by the double-layer shielding of the signal transmission unit 3, ensuring high-fidelity signal transmission.

[0094] The cable manufacturing method employs a step-by-step preparation and integration process. After each functional unit is independently prepared, they are integrated into a single unit through a cabling operation, sequentially forming the inner sheath 51, the tensile layer 6, and the outer sheath 52. The aramid fiber SZ double-layer stranded armor of the tensile layer 6 is a crucial step. The inner and outer layers are stranded in opposite directions. When the cable is subjected to axial tension, the torque generated by the inner and outer layers cancels each other out, preventing the cable from twisting under high tension. This ensures the structural stability of the cable in a vertically suspended state in deep sea conditions and avoids cable damage caused by accumulated torque.

[0095] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0096] Secondly: The accompanying drawings of the embodiments disclosed in this invention only involve the structures involved in the embodiments disclosed in this invention. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other.

[0097] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-voltage compensated gas-electric hybrid watertight cable, characterized in that, include: The ultra-high pressure gas unit (1) is located at the center of the cable and is used to transmit high pressure compensation gas; The ultra-high pressure gas unit (1) includes, from the inside out: a gas pipe inner wall (11) made of polyurethane material, a mesh anti-pressure layer (12) woven from aramid fibers, and a polyurethane gas pipe sheath (13) extruded on the outside of the anti-pressure layer (12). Several power supply units (2) are arranged on the outside of the ultra-high pressure gas unit (1) for transmitting electrical energy; the power supply unit (2) includes a stranded tin-plated copper conductor I (21) and a cross-linked polyethylene insulation layer (22) extruded on the outside of the conductor I (21). Several signal transmission units (3) are disposed on the outside of the ultra-high pressure gas unit (1) for transmitting data signals; the signal transmission unit (3) includes two stranded tin-plated copper conductors II (31), polytetrafluoroethylene propylene insulation layers (32) extruded on the outside of each conductor II (31), aluminum-plastic composite tape shielding layer (33) wrapped around the outside of the two polytetrafluoroethylene propylene insulation layers (32), and tin-plated copper wire braided shielding layer (34) woven on the outside of the aluminum-plastic composite tape shielding layer (33); Cable water-blocking adhesive (41) is used to fill the gaps between several power supply units (2) and several signal transmission units (3) after they are cabled together; Water-blocking tape (42) is wrapped around the outside of the cable water-blocking adhesive (41); The inner sheath (51) is extruded onto the outside of the wrapping water-blocking strip (42) and is made of high-strength elastomer polyurethane material; Tensile layer (6) is set outside the inner sheath (51), and is armored by high-strength aramid fiber using SZ double-layer twisting method, and is designed with torsion balance. The outer sheath (52) is extruded onto the outside of the tensile layer (6) and is made of high-strength elastomer polyurethane material.

2. The ultra-high voltage compensated gas-electric hybrid watertight cable according to claim 1, characterized in that: The inner diameter of the inner wall (11) of the gas pipe of the ultra-high pressure gas unit (1) ranges from 4 mm to 6 mm, and the wall thickness ranges from 1 mm to 3 mm.

3. The ultra-high voltage compensated gas-electric hybrid watertight cable according to claim 1, characterized in that: The stranded tin-plated copper conductor I (21) of the power supply unit (2) is made of multiple strands of tin-plated copper wire with a diameter ranging from 0.3 mm to 0.5 mm, and the stranding pitch ranges from 25 mm to 30 mm.

4. The ultra-high voltage compensated gas-electric hybrid watertight cable according to claim 1, characterized in that: The insulation layer thickness of the two stranded tin-plated copper conductors II (31) of the signal transmission unit (3) ranges from 0.1 mm to 0.2 mm, the wrapping overlap rate of the aluminum-plastic composite tape shielding layer (33) ranges from 20% to 30%, and the braiding density of the tin-plated copper wire braided shielding layer (34) ranges from 85% to 90%.

5. The ultra-high voltage compensated gas-electric hybrid watertight cable according to claim 1, characterized in that: The thickness of the inner sheath (51) ranges from 1.5 mm to 2 mm, and the thickness of the outer sheath (52) ranges from 2 mm to 3 mm.

6. A method for manufacturing an ultra-high voltage compensated gas-electric hybrid watertight cable as described in any one of claims 1-5, characterized in that, Includes the following steps: S1: Preparation of high-pressure gas unit (1): Select polyurethane hose as the inner wall of the gas tube (11), weave aramid fiber on the outside of the inner wall of the gas tube (11) to form a mesh-like pressure-resistant layer (12), and then squeeze polyurethane sheath on the outside of the pressure-resistant layer (12) as the gas tube sheath (13) to obtain the ultra-high pressure gas unit (1). S2: Preparation of power supply unit (2): Select stranded tin-plated copper conductor I (21), and extrude cross-linked polyethylene material on its outside to form a cross-linked polyethylene insulation layer (22), thereby obtaining power supply unit (2); S3: Preparation of signal transmission unit (3): Select two stranded tin-plated copper conductors II (31), and extrude polytetrafluoroethylene propylene on the outside of each conductor II (31) to form a polytetrafluoroethylene propylene insulation layer (32). Strand the two conductors II (31) with polytetrafluoroethylene propylene insulation layer (32) together, and wrap an aluminum-plastic composite tape around it as an aluminum-plastic composite tape shielding layer (33). Then braid tin-plated copper wire on the outside of the aluminum-plastic composite tape shielding layer (33) to form a tin-plated copper wire braided shielding layer (34), thereby obtaining the signal transmission unit (3). S4: Forming the first common cable core: The ultra-high pressure gas unit (1), multiple power supply units (2) and multiple signal transmission units (3) are arranged in a predetermined manner to form a cable. The gaps after the cable is formed are filled with cable water-blocking adhesive (41), and then water-blocking tape (42) is wrapped around the outside to form the first common cable core. S5: Forming a second community: High-strength elastomer polyurethane material is extruded outside the first community cable core to form an inner sheath (51), thus obtaining a second community; S6: Forming a third community: On the outside of the second community, high-strength aramid fibers are used for armoring in an SZ double-layer stranded armoring manner, and a torsional balance design is carried out to form a third community; S7: Forming the final cable: High-strength elastomer polyurethane material is extruded again on the outside of the third community to form an outer sheath (52), resulting in an ultra-high voltage compensated gas-electric hybrid watertight cable.

7. A method for manufacturing an ultra-high voltage compensated gas-electric hybrid watertight cable according to claim 6, characterized in that: In step S1, the inner diameter of the polyurethane hose ranges from 4 mm to 6 mm, and the wall thickness ranges from 1 mm to 3 mm; the braiding density of the aramid fiber is 6 to 8 knots per inch.

8. A method for manufacturing an ultra-high voltage compensated gas-electric hybrid watertight cable according to claim 6, characterized in that: In step S3, the wrapping overlap rate of the aluminum-plastic composite strip shielding layer (33) ranges from 20% to 30%, and the braiding density of the tin-plated copper wire braided shielding layer (34) ranges from 85% to 90%.

9. A method for manufacturing an ultra-high voltage compensated gas-electric hybrid watertight cable according to claim 6, characterized in that: In step S6, the SZ double-layer braided armor includes an inner layer braided in a first direction and an outer layer braided in a second direction opposite to the first direction to achieve torque balance.

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